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Support Structures Optimisation for High-Quality Metal Additive Manufacturing with Laser Powder Bed Fusion: A
Antonios Dimopoulos1, Mohamad Salimi2, Tat-Hean Gan1,2,3
1Department of Mechanical and Aerospace Engineering, Brunel University London, Uxbridge UB8 3PH, UK.
Materials (Basel, Switzerland)
|November 25, 2023
Summary
Optimizing support structures in metal additive manufacturing (AM) using Laser Powder Bed Fusion (LPBF) reduces residual stress and improves part quality. Block supports offer superior thermal performance, minimizing warping and enhancing component integrity.
Area of Science:
- Materials Science
- Mechanical Engineering
- Manufacturing Technology
Background:
- Metal Additive Manufacturing (AM) enables complex, lightweight components.
- Laser Powder Bed Fusion (LPBF) is a key AM technique but suffers from high residual stress, leading to part defects and failures.
Purpose of the Study:
- To evaluate the thermal behavior of various support structures in LPBF.
- To optimize support designs for reduced support volume and residual stress.
- To ensure high-quality prints in metal AM processes.
Main Methods:
- Experimental printing of L-shaped specimens using block-type supports on an LPBF machine.
- Numerical simulations to validate experimental findings and analyze line, contour, and cone supports.
- Design of Experiments (DOE) and multi-objective optimization for support structure assessment.
Main Results:
- Block supports demonstrated excellent thermal behavior during the LPBF process.
- High-density supports showed better temperature distribution compared to low-density supports.
- Cone-type supports were found to be more prone to warping issues.
Conclusions:
- Support structure design significantly impacts thermal behavior and residual stress in LPBF.
- Block and high-density supports are effective in mitigating defects and improving print quality.
- Findings offer guidance for advancing metal AM applications in aerospace, medical, and automotive sectors.
